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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Voltage Stability Constrained Moving Target Defense Against Net Load Redistribution Attacks

Moving target defense (MTD) using distributed flexible AC transmission system (D-FACTS) devices is a promising defense strategy to detect stealthy false data injection (FDI) attacks against the power system state estimation. However, all existing studies myopically perturb the reactance of D-FACTS lines without considering the system voltage stability. In this paper, we first illustrate voltage instability induced by MTDs in a three-bus system. To address this issue, we further propose a novel MTD framework that explicitly considers system voltage stability by using continuation power flow and voltage stability indices. We mathematically derive the sensitivity matrix of voltage stability index to line impedance, on which an optimization problem for maximizing voltage stability index is formulated. This framework is tested on the IEEE 14-bus and the IEEE 118-bus transmission systems, in which net load redistribution attacks are launched by sophisticated attackers. Here, the simulation results show the effectiveness of the proposed framework in circumventing the voltage instability while maintaining the detection effectiveness of MTD. We conduct case studies with and without the proposed framework under different MTD planning and operational methods. The impacts of the proposed two methods on attack detection effectiveness and system economic metrics are also revealed.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Enhanced grindability of bastnaesite ore by ex-situ CO 2 treatment under the partial pressure of 0-100 psi

High grinding energy consumption has long constrained the sustainable development of mineral processing. This study introduces an innovative technology that employs ex-situ CO 2 treatment to enhance the grindability of bastnaesite ore. The grinding aid effect was evaluated under CO 2 partial pressures ranging from 0 psi to 100 psi using particle size distribution and the Bond work index (BWI), while the underlying mechanism was elucidated with various characterization techniques including inductively coupled plasma (ICP), scanning electron microscopy (SEM), thermogravimetric analysis (TGA), and Brunauer-Emmett-Teller (BET). The optimal grinding aid effect was achieved at 100 psi partial pressure, 50% slurry concentration, and 3 h reaction duration. Correspondingly, the P80 of the grinding product decreased from 81.76 μm to 72.73 μm and the BWI of bastnaesite ore decreased from 6.96 kW·h/t to 6.30 kW·h/t, a reduction of 9.48%. The grinding aid effect primarily resulted from the transformation of sparingly soluble carbonates like calcite and dolomite into more soluble bicarbonates, which created substantial cracks and pores, thereby reducing the ore's hardness and improving its grindability. By significantly saving grinding energy consumption while delivering environmental benefits, this technology exhibits great promise for further optimization and widespread adoption.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Cystine-knot peptide inhibitors of HTRA1 bind to a cryptic pocket within the active site region

Cystine-knot peptides (CKPs) are naturally occurring peptides that exhibit exceptional chemical and proteolytic stability. We leveraged the CKP carboxypeptidase A1 inhibitor as a scaffold to construct phage-displayed CKP libraries and subsequently screened these collections against HTRA1, a trimeric serine protease implicated in age-related macular degeneration and osteoarthritis. The initial hits were optimized by using affinity maturation strategies to yield highly selective and potent picomolar inhibitors of HTRA1. Crystal structures, coupled with biochemical studies, reveal that the CKPs do not interact in a substrate-like manner but bind to a cryptic pocket at the S1’ site region of HTRA1 and abolish catalysis by stabilizing a non-competent active site conformation. The opening and closing of this cryptic pocket is controlled by the gatekeeper residue V221, and its movement is facilitated by the absence of a constraining disulfide bond that is typically present in trypsin fold serine proteases, thereby explaining the remarkable selectivity of the CKPs. Our findings reveal an intriguing mechanism for modulating the activity of HTRA1, and highlight the utility of CKP-based phage display platforms in uncovering potent and selective inhibitors against challenging therapeutic targets.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Modeling Flexible Generator Operating Regions via Chance- constrained Stochastic Unit Commitment

Here, we introduce a novel chance-constrained stochastic unit commitment model to address uncertainty in renewables' production uncertainty in power systems operation. For most thermal generators,underlying technical constraints that are universally treated as "hard" by deterministic unit commitment models are in fact based on engineering judgments, such that system operators can periodically request operation outside these limits in non-nominal situations, e.g., to ensure reliability. We incorporate this practical consideration into a chance-constrained stochastic unit commitment model, specifically by in-frequently allowing minor deviations from the minimum and maximum thermal generator power output levels. We demonstrate that an extensive form of our model is computationally tractable for medium-sized power systems given modest numbers of scenarios for renewables' production. We show that the model is able to potentially save significant annual production costs by allowing infrequent and controlled violation of the traditionally hard bounds imposed on thermal generator production limits. Finally, we conduct a sensitivity analysis of optimal solutions to our model under two restricted regimes and observe similar qualitative results.

42 ENGINEERING↗
DOE OSTI2024

Active interlocking metasurfaces enabled by shape memory alloys

Interlocking metasurfaces (ILMs) are a newly developed joining technology that relies on arrays of interlocking features that transmit force and constrain motion between adjoining bodies in one or more directions. This study explores harnessing the shape memory effect (SME) in Nickel-Titanium shape memory alloys (NiTi SMAs) in structures fabricated using additive manufacturing (AM) to advance the development of active ILMs by creating unit cells that open or close at specific temperatures. The study encompasses designing and fabricating two distinct interlocking array configurations using near-equiatomic NiTi powder and the laser powder bed fusion (L-PBF) AM technique, following a previously developed AM process optimization framework to manufacture defect-free parts. To guide the design process, finite element analysis (FEA) was employed to predict strain values during engage-disengage cycles. The martensitic transformation characteristics of the ILMs were characterized. Thermomechanical testing revealed that the ILMs demonstrate high locking force once engaged, coupled with complete shape recovery and good cyclic stability. Digital image correlation (DIC) was also employed to validate the FEA predictions during the engage-disengage cycles. The results indicate that NiTi SMA-based ILMs can be designed and fabricated into complex shapes using L-PBF. By leveraging the SME, the functionality of an ILM can be improved upon. The combination of computational modeling, additive manufacturing, and thermomechanical and physical property characterization provides a framework for designing future ILMs out of active materials.

Additive manufacturing↗
DOE OSTI2025

Simple model to investigate jet quenching and correlated errors for centrality-dependent nuclear modification factors in relativistic heavy-ion collisions

Here, we apply Bayesian techniques to compare a simple, empirical model for jet quenching in heavy-ion collisions to centrality-dependent jet R AA measured by ATLAS for Pb + Pb collisions at $\sqrt{s_{NN}}$ = 5.02 TeV. We find that the R AA values for central collisions are adequately described with a model for the mean p T -dependent jet energy loss using only two parameters. This model is extended by incorporating two-dimensional initial geometry information from TRENTo and compared to centrality-dependent R AA values. We find that the results are sensitive to the value of the jet-quenching formation time, τ ƒ , and that the optimal value of τ ƒ varies with the assumed path-length dependence of the energy loss. We construct a covariance error matrix for the data from the p T -dependent contributions to the ATLAS systematic errors and perform Bayesian calibrations for several different assumptions for the systematic error correlations. We show that the most-probable functions and $χ^2_d$ values are sensitive to assumptions made when fitting to correlated errors. This work demonstrates the utility of a simple model that can quickly demonstrate the constraining power of jet-quenching observables with corresponding uncertainties and guide future studies using more sophisticated models.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2023

EI_MS_ML

The unambiguous identification of compounds from their electron ionization mass (EI-MS) spectra remains a significant unsolved problem in the field of metabolomics and analytical chemistry as a whole. Typically EI-MS spectra are compared using various mathematical operations that convert the spectral similarity or differences into a distance-like metric that roughly approximates the similarity of any two spectra. A commonly used metric for this is the cosine similarity metric which has values close to one for very similar spectra and a value of zero for very dissimilar spectra; however, no metric is perfect. Due to the prevalence of structurally-similar compounds such as isomers and the prevalence of certain fragmentation patterns across structurally-dissimilar compounds, the unambiguous assignment of EI-MS spectra compounds remains difficult. Frequently, querying an observed EI-MS spectrum against a large database such as the NIST17 library yields multiple possible assignments requiring the end user to distinguish between multiple high scoring hits, or multiple low scoring hits while keeping in mind that the correct hit may not be in the database at all. Although techniques such as orthogonal information from techniques such as chromatography can greatly aid in unambiguous assignment, this also requires more complicated experimental designs and access to more complicated analytical instrumentation. Substructures can be trivially detected and represented as strings using a previously published technique called node coloring from a known chemical structure. However, for experimentally-derived EI-MS spectra this information must be derived from the spectra itself (i.e., because we do not know what compound it represents). To achieve this, the software uses techniques from the field of machine learning and a large training dataset of EI-MS spectra corresponding to known structures annotated with substructure strings, to build models that can predict the presence of a given chemical substructure from an EI-MS spectrum directly.If these predictions are of high-quality (i.e., are unlikely to be false positives), the presence of one or more predicted substructures can be used to constrain the number of possible hits for a query spectrum. Mathematically, this restriction could be expressed in many forms, but the most straight-forward implementation is to weight the cosine similarity of a query spectrum and a plausible database match with a Tanimoto-like coefficient based on the ratio of the number of substructures predicted to the number of substructures present in the potential database hit. Determining which combination of models best reduces assignment ambiguity will be achieved using a combination of manual curation and optimization techniques such as genetic algorithms. This software will perform all the steps necessary to construct said models from a training dataset and evaluate them using a holdout dataset. Various statistical analyses can be performed to determine if this approach does decrease assignment ambiguity. For example, if this approach works, on average, the rank-order of the correct assignment for the holdout set of EI-MS spectra should decrease and the weighted cosine similarities for most of the possible matches in the database should be better than the unweighted cosine similarities. Furthermore, this same pipeline can be used on real experimental data to generate less ambiguous assignments.

Mitchell, Joshua↗
DOE OSTI2021

Secure LoRa Firmware Update with Adaptive Data Rate Techniques

Internet of Things (IoT) devices rely upon remote firmware updates to fix bugs, update embedded algorithms, and make security enhancements. Remote firmware updates are a significant burden to wireless IoT devices that operate using low-power wide-area network (LPWAN) technologies due to slow data rates. One LPWAN technology, Long Range (LoRa), has the ability to increase the data rate at the expense of range and noise immunity. The optimization of communications for maximum speed is known as adaptive data rate (ADR) techniques, which can be applied to accelerate the firmware update process for any LoRa-enabled IoT device. In this paper, we investigate ADR techniques in an application that provides remote monitoring of cattle using small, battery-powered devices that transmit data on cattle location and health using LoRa. In addition to issues related to firmware update speed, there are significant concerns regarding reliability and security when updating firmware on mobile, energy-constrained devices. A malicious actor could attempt to steal the firmware to gain access to embedded algorithms or enable faulty behavior by injecting their own code into the device. A firmware update could be subverted due to cattle moving out of the LPWAN range or the device battery not being sufficiently charged to complete the update process. To address these concerns, we propose a secure and reliable firmware update process using ADR techniques that is applicable to any mobile or energy-constrained LoRa device. The proposed system is simulated and then implemented to evaluate its performance and security properties.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

SymbolNet: neural symbolic regression with adaptive dynamic pruning for compression

Abstract Compact symbolic expressions have been shown to be more efficient than neural network (NN) models in terms of resource consumption and inference speed when implemented on custom hardware such as field-programmable gate arrays (FPGAs), while maintaining comparable accuracy (Tsoi et al 2024 EPJ Web Conf. 295 09036). These capabilities are highly valuable in environments with stringent computational resource constraints, such as high-energy physics experiments at the CERN Large Hadron Collider. However, finding compact expressions for high-dimensional datasets remains challenging due to the inherent limitations of genetic programming (GP), the search algorithm of most symbolic regression (SR) methods. Contrary to GP, the NN approach to SR offers scalability to high-dimensional inputs and leverages gradient methods for faster equation searching. Common ways of constraining expression complexity often involve multistage pruning with fine-tuning, which can result in significant performance loss. In this work, we propose S y m b o l N e t , a NN approach to SR specifically designed as a model compression technique, aimed at enabling low-latency inference for high-dimensional inputs on custom hardware such as FPGAs. This framework allows dynamic pruning of model weights, input features, and mathematical operators in a single training process, where both training loss and expression complexity are optimized simultaneously. We introduce a sparsity regularization term for each pruning type, which can adaptively adjust its strength, leading to convergence at a target sparsity ratio. Unlike most existing SR methods that struggle with datasets containing more than O ( 10 ) inputs, we demonstrate the effectiveness of our model on the LHC jet tagging task (16 inputs), MNIST (784 inputs), and SVHN (3072 inputs).

Tsoi, Ho Fung (ORCID:0000000225502184)↗
DOE OSTI2026

In-Band Scattering and Absorption of Infrared Blocking Foam Filters for Millimeter-wave Cameras

Expanded closed-cell polymer foams are widely used as thermal infrared (IR) blocking filters in millimeter-wave cameras, particularly for Cosmic Microwave Background observations. Precise knowledge of their millimeter-wave properties is essential for optimizing sensitivity. We present broadband (150 GHz - 2 THz) transmittance spectroscopy of Styroace-II and several Zotefoam filters, fitting their spectra with a radiative transfer model incorporating dielectric absorption and Rayleigh, Mie, and higher-order scattering. For a typical 5~cm thick filter stack at 280~GHz, Styroace-II exhibits ${\sim}10\%$ scattering with absorption estimated as ${\lesssim}5\%$ by effective-medium theory, while Zotefoam HD30 offers superior performance at ${\sim}3\%$ scattering and absorption likewise bounded to ${{\lesssim}0.3\%}$. Each model component is constrained at the ${\sim}0.1\%$ transmittance level for millimeter wavelengths. We observe batch-to-batch scattering variability of up to 2 percentage points in foams with multiple tested batches. Less commonly used Zotefoam formulations (LD15 and LD24) can further reduce in-band scattering to ${<}1\%$ while maintaining negligible in-band absorption and likely comparable IR blocking due to shared polyethylene absorption features and similar cell sizes. Based on this work, a filter constructed from the best measured LD24 batch has replaced the Styroace-II filter in a Simons Observatory 220/280 GHz Small Aperture Telescope.

Thomas, Alex [Chicago U., Astron. Astrophys. Ctr.;↗
DOE OSTI2022

Role of hot electrons in shock ignition constrained by experiment at the National Ignition Facility

Shock ignition is a scheme for direct drive inertial confinement fusion that offers the potential for high gain with the current generation of laser facility; however, the benefits are thought to be dependent on the use of low adiabat implosions without laser–plasma instabilities reducing drive and generating hot electrons. A National Ignition Facility direct drive solid target experiment was used to calibrate a 3D Monte Carlo hot-electron model for 2D radiation-hydrodynamic simulations of a shock ignition implosion. The α = 2.5 adiabat implosion was calculated to suffer a 35% peak areal density decrease when the hot electron population with temperature T ℎ = 55 keV and energy E ℎ = 13 kJ was added to the simulation. Optimizing the pulse shape can recover ~1/3 of the peak areal density lost due to a change in shock timing. Here, despite the harmful impact of laser–plasma instabilities, the simulations indicate shock ignition as a viable method to improve performance and broaden the design space of near ignition high adiabat implosions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Demonstrate FARM supervisory capabilities for a thermal energy storage problem for the DETAIL facility: IES Simulation Ecosystem Control System Development

The goal of the power dispatch problem for an Integrated Energy System (IES) is to adjust the power output and the heat flow of each component to maximize the profitability of the whole unit. Facilities that can integrate real-time digital signals, mock nuclear power, thermal energy storage and industrial heat use via high-temperature electrolysis were constructed at INL to support the research activities. The Dynamic Energy Technology and Integration Laboratory (DETAIL) houses the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET) and the Thermal Energy Distribution System (TEDS). In this report, the hierarchical control system architecture proposed in June 2023 milestone for the flexible operation of DETAIL facility is finalized and demonstrated. A brief description of the components and the corresponding Dymola models from the HYRBID repository is first provided. Then, the current control strategy is presented. In particular, the approach for generating the set-point trajectories to be fed to the PI controllers is analyzed, and its limits were identified. To preserve safe operation over both long-time and real-time horizons, the integration of a Supervisory Control layer embedding a modified version of FARM (Feasible Actuator Range Modifier) module is proposed. FARM is a component of the RAVEN-based FORCE framework designed to support HERON module at optimizing the operation of IES units. The proposed control system for DETAIL foresees FARM to be applied twice, i.e., the original version (“FARM-Validator”) aiding the solution of the power dispatch problem, and a modified version (“FARM-Supervisory”) coordinating the PID controllers. Despite the kernel of the two modules is the same, their tasks are quite different. The former intervenes at the beginning of each hour to prevent constraint violations over long time periods, the latter addresses real-time control tasks and monitors the response of constrained variables at a much finer time resolution. A tentative procedure for training the embedded Digital Twins with the experimental data is also proposed. Finally, the capabilities of the designed architecture and the impact of the added Supervisory Control layer are demonstrated by simulating a representative power dispatch scenario.

25 ENERGY STORAGE↗
DOE OSTI2022

A Logarithmic Bayesian Approach to Quantum Error Detection

We consider the problem of continuous quantum error correction from a Bayesian perspective, proposing a pair of digital filters using logarithmic probabilities that are able to achieve near-optimal performance on a three-qubit bit-flip code, while still being reasonable to implement on low-latency hardware. These practical filters are approximations of an optimal filter that we derive explicitly for finite time steps, in contrast with previous work that has relied on stochastic differential equations such as the Wonham filter. By utilizing logarithmic probabilities, we are able to eliminate the need for explicit normalization and can reduce the Gaussian noise distribution to a simple quadratic expression. The state transitions induced by the bit-flip errors are modeled using a Markov chain, which for log-probabilities must be evaluated using a LogSumExp function. We develop the two versions of our filter by constraining this LogSumExp to have either one or two inputs, which favors either simplicity or accuracy, respectively. Using simulated data, we demonstrate that the single-term and two-term filters are able to significantly outperform both a double threshold scheme and a linearized version of the Wonham filter in tests of error detection under a wide variety of error rates and time steps.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Feasible Actuator Range Modifier (FARM), a Tool Aiding the Solution of Unit Dispatch Problems for Advanced Energy Systems

Integrated energy systems (IESs) seek to minimize power generating costs in future power grids through the coupling of different energy technologies. To accommodate fluctuations in load demand due to the penetration of renewable energy sources, flexible operation capabilities must be fully exploited, and even power plants that are traditionally considered as base-load units need to be operated according to unconventional paradigms. Thermomechanical loads induced by frequent power adjustments can accelerate the wear and tear. If a unit is flexibly operated without respecting limits on materials, the risk of failures of expensive components will eventually increase, nullifying the additional profits ensured by flexible operation. In addition to the bounds on power variations (explicit constraints),the solution of the unit dispatch problem needs to meet the limits on the variation of key process variables, including temperature, pressure and flow rate (implicit constraints).The FARM (Feasible Actuator Range Modifier) module was developed to enable existing optimization algorithms to identify solutions to the unit dispatch problem that are both economically favorable and technologically sustainable. Thanks to the iterative dispatcher–validator scheme, FARM permits addressing all the imposed constraints without excessively increasing the computational costs. In this work, the algorithms constituting the module are described, and the performance was assessed by solving the unit dispatch problem for an IES composed of three units, i.e., balance of plant, gas turbine, and high-temperature steam electrolysis. Finally, the FARM module provides dedicated tools for visualizing the response of the constrained variables of interest during operational transients and a tool aiding the operator at making decisions. These techniques might represent the first step towards the deployment of an ecological interface design (EID) for IES units.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Accelerating defect predictions in semiconductors using graph neural networks

First-principles computations reliably predict the energetics of point defects in semiconductors but are constrained by the expense of using large supercells and advanced levels of theory. Machine learning models trained on computational data, especially ones that sufficiently encode defect coordination environments, can be used to accelerate defect predictions. Here, we develop a framework for the prediction and screening of native defects and functional impurities in a chemical space of group IV, III–V, and II–VI zinc blende semiconductors, powered by crystal Graph-based Neural Networks (GNNs) trained on high-throughput density functional theory (DFT) data. Using an innovative approach of sampling partially optimized defect configurations from DFT calculations, we generate one of the largest computational defect datasets to date, containing many types of vacancies, self-interstitials, anti-site substitutions, impurity interstitials and substitutions, as well as some defect complexes. We applied three types of established GNN techniques, namely crystal graph convolutional neural network, materials graph network, and Atomistic Line Graph Neural Network (ALIGNN), to rigorously train models for predicting defect formation energy (DFE) in multiple charge states and chemical potential conditions. We find that ALIGNN yields the best DFE predictions with root mean square errors around 0.3 eV, which represents a prediction accuracy of 98% given the range of values within the dataset, improving significantly on the state-of-the-art. We further show that GNN-based defective structure optimization can take us close to DFT-optimized geometries at a fraction of the cost of full DFT. The current models are based on the semi-local generalized gradient approximation-Perdew–Burke–Ernzerhof (PBE) functional but are highly promising because of the correlation of computed energetics and defect levels with higher levels of theory and experimental data, the accuracy and necessity of discovering novel metastable and low energy defect structures at the PBE level of theory before advanced methods could be applied, and the ability to train multi-fidelity models in the future with new data from non-local functionals. The DFT-GNN models enable prediction and screening across thousands of hypothetical defects based on both unoptimized and partially optimized defective structures, helping identify electronically active defects in technologically important semiconductors.

Rahman, Md Habibur (ORCID:000000027705984X)↗
DOE OSTI2025

Optimizing cost-effective and benchmarked industry standards to quantify nutrient bioextraction by seaweed

Interest in the utility of seaweed farms to mitigate coastal eutrophication, or nutrient loading, has grown commensurate with the recent rise of the farmed seaweed industry in the U.S. But economic valuation of this ecosystem service remains elusive in part because of challenges in quantifying this spatiotemporally variable biological process with reproducible and comparable metrics. Regulatory bodies that permit wastewater discharge or lease area for aquaculture farms require water quality testing and reporting of dissolved total nitrogen (N) in nearshore marine environments. These metrics must meet EPA standards for testing and reporting (e.g., Total Kjeldahl Nitrogen - TKN). However, these metrics are inherently highly variable over space and time in dynamic nearshore systems, and expensive to evaluate with sufficient breadth to constrain this variance, creating a critical bottleneck to direct quantification of farmed seaweed net uptake rates in situ.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Bifunctional nanoprecipitates strengthen and ductilize a medium-entropy alloy

Single-phase high- and medium-entropy alloys with face-centred cubic (fcc) structure can exhibit high tensile ductility and excellent toughness, but their room-temperature strengths are low. Dislocation obstacles such as grain boundaries, twin boundaries, solute atoms and precipitates can increase strength. However, with few exceptions, such obstacles tend to decrease ductility. Interestingly, precipitates can also hinder phase transformations. Here, using a model, precipitate-strengthened, Fe–Ni–Al–Ti medium-entropy alloy, we demonstrate a strategy that combines these dual functions in a single alloy. The nanoprecipitates in our alloy, in addition to providing conventional strengthening of the matrix, also modulate its transformation from fcc-austenite to body-centred cubic (bcc) martensite, constraining it to remain as metastable fcc after quenching through the transformation temperature. During subsequent tensile testing, the matrix progressively transforms to bcc-martensite, enabling substantial increases in strength, work hardening and ductility. This use of nanoprecipitates exploits synergies between precipitation strengthening and transformation-induced plasticity, resulting in simultaneous enhancement of tensile strength and uniform elongation. Further, our findings demonstrate how synergistic deformation mechanisms can be deliberately activated, exactly when needed, by altering precipitate characteristics (such as size, spacing, and so on), along with the chemical driving force for phase transformation, to optimize strength and ductility.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Highly dense atomic Fe–Ni dual metal sites for efficient CO 2 to CO electrolyzers at industrial current densities

Carbon-supported, atomically dispersed, nitrogen-coordinated metal sites (e.g., Fe and Ni) are arguably the most promising catalysts for the electrochemical reduction of CO 2 to CO due to their unique catalytic properties and the use of earth-abundant elements. However, conventional single metal sites are constrained by their structural simplicity, causing either too weak or too strong absorption/desorption of multiple critical intermediates (e.g., *COOH and *CO). Current catalysts also suffer from ultra-low loadings (<1.0 wt%) of atomic metal active sites in catalysts, leading to inadequate performance for CO 2 -to-CO conversion. Here, we develop dual Ni/Fe metal site catalysts with significantly increased atomically dispersed metal loadings (up to 4.8 wt%). A gas-phase chemical vapor deposition (CVD) approach to introducing single Ni sites was integrated with Fe 2 O 3 /ZIF-8 precursors, followed by an optimal thermal activation. The optimized CVD-Ni/Fe–N–C catalyst exhibited remarkable electrocatalytic performance for the CO 2 reduction to CO in a continuous membrane-electrode-assembly electrolyzer, achieving a maximum CO faradaic efficiency (FE CO ) of 96% at a current density of 700 mA cm −2 in a near-neutral electrolyte. Furthermore, a desirable but challenging acidic flow-cell electrolyzer was designed using this dual metal site catalyst to improve CO 2 utilization, accomplishing a FE CO of up to 95% at a CO partial current density close to 600 mA cm −2 . Density functional theory (DFT) calculations suggest a synergetic effect between Fe–Ni pairs facilitating *COOH intermediate formation and *CO desorption simultaneously during CO 2 to CO conversion. This is key to breaking the linear scaling relationship of conventional single-metal site catalysts during the CO 2 reduction reaction.

36 MATERIALS SCIENCE↗